Floor panel for forming a floor covering

ABSTRACT

A floor panel for forming a floor covering comprises a substrate consisting of at least two substrate layers differing in density and, on at least one pair of opposite edges, is provided with coupling parts of the so-called push-lock type. Vertically active locking surfaces, where they cooperate in the coupled condition of two of such floor panels, define a tangent line which is horizontal or does not deviate more than 50 degrees from the horizontal. The locking surfaces are situated closer to the upper side of the first substrate layer than to the lower side of the first substrate layer.

BACKGROUND OF THE INVENTION 1. Field of the Invention

This invention relates to a floor panel for forming a floor covering,more particularly for forming a floor covering which can be installed onan underlying surface.

More particularly, the invention relates to a floor panel for forming afloor covering of the type wherein the floor panel comprises asubstrate; wherein the floor panel comprises coupling parts on at leasttwo opposite edges, which coupling parts allow that two of such floorpanels can be coupled to each other by means of a downward movement ofone floor panel in respect to the other floor panel; wherein thecoupling parts, in the coupled condition of two of such floor panels,form a first locking system which effects a locking in a first directionin the plane of the floor panels and perpendicular to said edges, aswell as form a second locking system which effects a locking in a seconddirection transverse to the plane of the floor panels; wherein the firstlocking system is formed at least of an upward-directed lowerhook-shaped part which is situated on one of said two opposite edges, aswell as a downward-directed upper hook-shaped part which is situated onthe other, opposite edge of said two opposite edges, which hook-shapedparts can be engaged behind each other by means of said downwardmovement; wherein the lower hook-shaped part consists of a lip with anupward-directed locking element, whereas the upper hook-shaped partconsists of a lip with a downward-directed locking element; wherein thesecond locking system comprises locking parts, which respectively aresituated in the proximity of the proximal extremity of the lowerhook-shaped part and the distal extremity of the upper hook-shaped part.

2. Related Art

Such type of floor panel is known, amongst others, from the document WO2011/077311.

A general problem with such floor panels is obtaining a good balancebetween, on the one hand, the strength or solidity of the lockingbetween the coupled floor panels and, on the other hand, the ease ofinstallation of the floor panels.

SUMMARY OF THE DISCLOSURE

The present invention primarily aims at an alternative floor panel forforming a floor covering, of the aforementioned type. More particularly,the aim of this invention consists in that such floor covering can beinstalled easily, however, while still sufficient strength is maintainedin the floor covering.

The inventor has found that this aim can be achieved by applying certainstructural features and/or material characteristics of the substrate incombination with certain characteristics in the realization of thecoupling parts.

These specific combinations of structural features and/or materialcharacteristics of the substrate and characteristics in the realizationof the coupling parts will be described herein below in six independentaspects of the present invention.

According to a first independent aspect thereof, the invention relatesto a floor panel for forming a floor covering, of the aforementionedtype, with the characteristic that said substrate relates to a composedsubstrate which consists at least of two substrate layers, to with afirst synthetic material-based substrate layer and a second substratelayer situated preferably directly there above, which second substratelayer has a thickness of at least 0.5 mm and preferably at least 1 mm;that the density of the first substrate layer differs from the densityof the second substrate layer, and preferably the second substrate layerhas a higher density than the first substrate layer; that said lockingparts are provided with locking surfaces, which, there, where theycooperate in the coupled condition of two of such floor panels, define atangent line which is horizontal or does not deviate more than 50degrees from the horizontal; and that said locking surfaces are situatedcloser to the upper side of the first substrate layer than to the lowerside of the first substrate layer, irrespective whether these lockingsurfaces are situated in or not in said second substrate layer.

As the locking surfaces, there, where they cooperate in the coupledcondition of two of such floor panels, define a tangent line which ishorizontal or does not deviate more than 50 degrees from the horizontal,the advantage is obtained that a strong vertical locking can be providedbetween the coupled floor panels. However, the ease of installation ofthe floor panels still can be guaranteed by the specific location of thelocking surfaces in respect to the substrate layers having a differentdensity. That the density of these substrate layers is differentmoreover offers the possibility of optimizing them in function of thefeatures they have to supply, for example, in respect to strength and/orelasticity.

According to an independent second aspect thereof, the present inventionrelates to a floor panel for forming a floor covering, of theaforementioned type, with the characteristic that said substrate relatesto a composed substrate which consists at least of two substrate layers,to with a first synthetic material-based substrate layer and a secondsubstrate layer situated preferably directly there above, which secondsubstrate layer has a thickness of at least 0.5 mm and preferably atleast 1 mm; that the first substrate layer is foamed, preferably is ofthe closed cell-type and still more preferably is of the so-called hardfoam type, and preferably the second substrate layer is not foamed or isless foamed than the first substrate layer; that said locking parts areprovided with locking surfaces, which, there, where they cooperate inthe coupled condition of two of such floor panels, define a tangent linewhich is horizontal or does not deviate more than 50 degrees from thehorizontal; and that said locking surfaces are situated closer to theupper side of the first substrate layer than to the lower side of thefirst substrate layer, irrespective whether these locking surfaces aresituated in or not in said second substrate layer.

As the locking surfaces, there, where they cooperate in the coupledcondition of two of such floor panels, define a tangent line which ishorizontal or does not deviate more than 50 degrees from the horizontal,the advantage is obtained that a strong vertical locking can be providedbetween the coupled floor panels. However, the ease of installation ofthe floor panels still can be guaranteed by the specific location of thelocking surfaces in respect to the respective substrate layers. That thesynthetic material-based substrate layer is foamed, moreover offers thepossibility of providing this substrate layer with useful features, suchas in respect to hardness and/or deformability.

In a particular embodiment, the first substrate layer is foamedgradually, wherein the degree of foaming may increase in downward or inupward direction.

According to an independent third aspect thereof, the present inventionrelates to a floor panel for forming a floor covering, of theaforementioned type, with the characteristic that said substrate relatesto a composed substrate which consists at least of two substrate layers,to with a first synthetic material-based substrate layer and a secondsubstrate layer situated preferably directly there above, which secondsubstrate layer has a thickness of at least 0.5 mm and preferably atleast 1 mm; that the first substrate layer is extruded; that saidlocking parts are provided with locking surfaces, which, there, wherethey cooperate in the coupled condition of two of such floor panels,define a tangent line which is horizontal or does not deviate more than50 degrees from the horizontal; and that said locking surfaces aresituated closer to the upper side of the first substrate layer than tothe lower side of the first substrate layer, irrespective whether theselocking surfaces are situated in or not in said second substrate layer.

As the locking surfaces, there, where they cooperate in the coupledcondition of two of such floor panels, define a tangent line which ishorizontal or does not deviate more than 50 degrees from the horizontal,the advantage is obtained that a strong vertical locking can be providedbetween the coupled floor panels. However, the ease of installation ofthe floor panels still can be guaranteed by the specific location of thelocking surfaces in respect to the respective substrate layers. That thesynthetic material-based substrate layer is extruded, moreover offersthe possibility of providing, in a simple and efficient manner, thissubstrate layer with functional features, such as in respect to rigidityand/or dimensional stability.

According to an independent fourth aspect thereof, the present inventionrelates to a floor panel for forming a floor covering, of theaforementioned type, with the characteristic that said substrate relatesto a composed substrate which consists at least of two substrate layers,to with a first synthetic material-based substrate layer and a secondsubstrate layer situated preferably directly there above, which secondsubstrate layer has a thickness of at least 0.5 mm and preferably atleast 1 mm; that both substrate layers are glued to each other,preferably by means of a waterproof glue; that said locking parts areprovided with locking surfaces, which, there, where they cooperate inthe coupled condition of two of such floor panels, define a tangent linewhich is horizontal or does not deviate more than 50 degrees from thehorizontal; and that said locking surfaces are situated closer to theupper side of the first substrate layer than to the lower side of thefirst substrate layer, irrespective whether these locking surfaces aresituated in or not in said second substrate layer.

As the locking surfaces, there, where they cooperate in the coupledcondition of two of such floor panels, define a tangent line which ishorizontal or does not deviate more than 50 degrees from the horizontal,the advantage is obtained that a strong vertical locking can be providedbetween the coupled floor panels. However, the ease of installation ofthe floor panels still can be guaranteed by the specific location of thelocking surfaces in respect to the respective substrate layers. That thesubstrate is composed and is constructed of glued substrate layers,moreover offers the possibility of configuring each of these substratelayers in function of the features which they have to provide, such asin respect to elasticity and/or strength.

According to an independent fifth aspect thereof, the present inventionrelates to a floor panel for forming a floor covering, of theaforementioned type, with the characteristic that said substrate relatesto a composed substrate which consists at least of two substrate layers,to with a first synthetic material-based substrate layer and a secondsubstrate layer situated preferably directly there above, which secondsubstrate layer has a thickness of at least 0.5 mm and preferably atleast 1 mm; that said substrate layers are made according to any of thefollowing possibilities or according to a combination thereof:

-   -   the density of the first substrate layer is different from the        density of the second substrate layer, and preferably the second        substrate layer has a higher density than the first substrate        layer;    -   the first substrate layer is foamed and preferably is of the        closed cell-type and still more preferably of the so-called hard        foam-type, and preferably the second substrate layer is not        foamed or is less foamed than the first substrate layer; the        first substrate layer is extruded; and/or    -   both substrate layers are glued to each other, preferably by        means of a waterproof glue;        that said locking parts are provided with locking surfaces,        which, there, where they cooperate in the coupled condition of        two of such floor panels, define a tangent line which is        horizontal or does not deviate more than 50 degrees from the        horizontal; that said locking surfaces are at least partially        situated in the first substrate layer, and preferably are        situated therein entirely; that said upward-directed locking        element and said downward-directed locking element each are        provided with a locking surface, which locking surfaces, in the        coupled condition of two of such floor panels, cooperate; and        that the locking distance is smaller than 1 cm, preferably        smaller than 5 mm, and still more preferably smaller than 3 mm,        which locking distance is formed by the horizontal distance        between a vertical closing plane formed between two of such        floor panels in the coupled condition, and a vertical plane        through the middle of the zone over which said locking surfaces        of the locking elements contact each other in the coupled        condition.

As the locking surfaces, there, where they cooperate in the coupledcondition of two of such floor panels, define a tangent line which ishorizontal or does not deviate more than 50 degrees from the horizontal,the advantage is obtained that a strong vertical locking can be providedbetween the coupled floor panels. Moreover, the locking distance isrelatively small, which allows performing the hook-shaped partsrelatively compact, which is beneficial for the strength of thecoupling. However, the ease of installation of the floor panels stillcan be guaranteed by the at least partial location of the lockingsurfaces in the first substrate layer. That the substrate is composedand is realized according to any of the possibilities mentioned in therespective aspect, moreover offers the possibility of configuring eachof the mentioned substrate layers in function of the features they haveto provide, such as in respect to elasticity and/or strength.

According to an independent sixth aspect thereof, the present inventionrelates to a floor panel for forming a floor covering, of theaforementioned type, with the characteristic that said substrate relatesto a composed substrate which consists at least of two substrate layers,to with a first synthetic material-based substrate layer and a secondsubstrate layer situated preferably directly there above, which secondsubstrate layer has a thickness of at least 0.5 mm and preferably atleast 1 mm; that said substrate layers are made according to any of thefollowing possibilities or according to a combination thereof:

-   -   the density of the first substrate layer is different from the        density of the second substrate layer, and preferably the second        substrate layer has a higher density than the first substrate        layer;    -   the first substrate layer is foamed and preferably is of the        closed cell-type and still more preferably of the so-called hard        foam-type, and preferably the second substrate layer is not        foamed or is less foamed than the first substrate layer; the        first substrate layer is extruded; and/or    -   both substrate layers are glued to each other, preferably by        means of a waterproof glue;        that said locking parts are provided with locking surfaces,        which, there, where they cooperate in the coupled condition of        two of such floor panels, define a tangent line which is        horizontal or does not deviate more than 50 degrees from the        horizontal; and that said locking surfaces are at least        partially situated in the second substrate layer, and preferably        are situated therein entirely.

As the locking surfaces, there, where they cooperate in the coupledcondition of two of such floor panels, define a tangent line which ishorizontal or does not deviate more than 50 degrees from the horizontal,the advantage is obtained that a strong vertical locking can be providedbetween the coupled floor panels. However, the ease of installation ofthe floor panels still can be guaranteed by the at least partiallocation of the locking surfaces in the second substrate layer. That thesubstrate is composed and is realized according to any of thepossibilities mentioned in the respective aspect, moreover offers thepossibility of configuring each of the mentioned substrate layers infunction of the features they have to provide, such as in respect toelasticity and/or strength.

It is also noted that any of the characteristics of any of the sixindependent aspects of the present invention can be combined at choicewith any characteristic of another of the six independent aspects, asfar as such combination is not contradictory.

Preferred and alternative embodiments of the present invention accordingto the six independent aspects are described herein below.

The first substrate layer of the composed substrate is syntheticmaterial-based. Preferably, it comprises at least a thermoplasticmaterial, wherein by “thermoplastic material” a material has to beunderstood which comprises at least a thermoplastic synthetic material.In other words, the first substrate layer preferably comprises at leasta thermoplastic material, or this substrate layer is at least realizedon the basis thereof.

Examples of synthetic materials which can be applied when realizing thefirst substrate layer relate to polyvinyl chloride, polyethylene,polypropylene, polyethylene terephthalate, polyurethane or a combinationof two or more of the herein above-mentioned synthetic materials.

Preferably, the first substrate layer is a filled synthetic materialcomposite. By this is meant that the first substrate layer, apart from asynthetic material, also comprises a filling. This filling may consistof one or a combination of the following materials: bamboo, cork, and/orwood. In particular, the filling consists of one or a combination of theherein above-mentioned materials in the form of fibers and/or dustand/or powder.

In case that the first substrate layer is made as a filled syntheticmaterial composite, this substrate layer can also be foamed. Then itpreferably is of the closed cell-type.

More generally, the first substrate layer can be foamed, independentlyof the embodiment of this substrate layer as a filled synthetic materialcomposite. Preferably, this foaming leads to a density reduction of atleast 10% or still better to a density reduction of at least 20%. Morefavorably, a density reduction between 20% and 60% is achieved.

The first substrate layer of the composed substrate can comprise atleast one or more plasticizers. However, this first substrate layerpreferably is of the rigid type. In other words, it is preferred thatthe first substrate layer does not contain any plasticizers. In casethat plasticizers are applied indeed, those preferably are present in anamount of less than 20 phr and still more preferably in an amountbetween 5 and 15 phr.

Preferably, the first substrate layer comprises fillers, such as chalk,limestone and/or talc, which may or may not be applied in combinationwith the aforementioned filling.

In order to increase the stability of the first substrate layer, thissubstrate layer can be provided with at least one reinforcement layer,which preferably is made of glass fiber or the like. In particular, thereinforcement layer relates to a glass fiber cloth.

In practice, the first substrate layer preferably has a thickness of atleast 3 mm, more preferably a thickness of at least 4 mm and still morepreferably a thickness of at least 5 mm.

Preferably, the first substrate layer constitutes more than half of thethickness of the floor panel. In particular, this substrate layerdetermines the rigidity or solidity of the substrate of the floor panel.

The first and/or second substrate layer of the composed substratepreferably is realized water-resistant.

The second substrate layer of the composed substrate, just like thefirst substrate layer, preferably is synthetic material-based. It thenpreferably comprises a thermoplastic material, which preferably is ofthe soft or supple type.

Preferably, the second substrate layer can be realized on the basis ofvinyl, such as polyvinyl chloride, more particularly soft polyvinylchloride, polyethylene, more particularly soft polyethylene,polyurethane, polypropylene, polyethylene terephthalate or a combinationof the above.

In order to provide the second substrate layer with a certain softnessor suppleness, one or more plasticizers can be added thereto.Preferably, these plasticizers are present in an amount of more than 15phr and more preferably even in an amount of minimum 20 phr.

Fillers, such as chalk, limestone and/or talc may also be added to thesecond substrate layer.

According to an alternative, the second substrate layer consists of oneor a combination of the following materials: veneer, rubber, linoleum orany material, more particular cork, bamboo, or veneer, coated by vinylor resin.

With the aim of increasing the stability, the second substrate layer canbe provided with at least one reinforcement layer, preferably of glassfiber or the like.

The floor panel may comprise a backing layer, which preferably islocated directly underneath the first substrate layer. The backing layerpreferably shows one or a combination of the following characteristics:

-   -   the backing layer consists of a thermoplastic synthetic material        layer and/or of a hot-melt glue;    -   the backing layer is realized on the basis of one or more of the        following materials: cork, rubber and/or foam.

The backing layer may provide the floor panel with acoustic features,such that, for example, footfall sound during walking on installed floorpanels is dampened.

The floor panel may comprise a top layer, whether or not consisting of aplurality of layers, which top layer preferably is situated directlyabove the second substrate layer. The top layer may comprise one or acombination of the following characteristics:

-   -   the top layer comprises at least a decorative layer, preferably        in the form of a print, preferably provided on a foil or film,        which foil or film preferably is of a thermoplastic kind;    -   the top layer comprises at least a translucent or transparent        wear layer, which preferably relates to a foil or film, in        particular of the thermoplastic type.

In an alternative embodiment, the second substrate layer can be providedwith a backing layer on the lower side of the second substrate layer,wherein this backing layer may or may not be combined with said toplayer.

Preferably, the floor panel has a thickness which is smaller than 10 mm,still better in the order of magnitude of 8 mm, or possibly thinner.

The aforementioned composed substrate substantially is realized massive.

The composed substrate of the present invention is particularly suitedfor making the downward-directed locking element and/or theupward-directed locking element substantially massive. This offers theadvantage that the strength of the locking can even be enhanced.

The downward-directed locking element and the upward-directed lockingelement each may be provided with a locking surface, which lockingsurfaces, in the coupled condition of two of such floor panels,cooperate. There, where they cooperate in the coupled condition of twoof such floor panels, these locking surfaces preferably define a tangentline which is situated vertically or does not deviate more than 45degrees from the vertical. Hereby, the advantage is obtained that astrong horizontal locking can be provided, which is beneficial for thegeneral strength of the coupling.

In order to still improve the smoothness of installation, the proximalextremity of the upper hook-shaped part and/or the distal extremity ofthe lower hook-shaped part preferably is free from locking parts. In thecoupled condition of two of such floor panels, the distal extremity ofthe lower hook-shaped part even preferably is separated from theopposite floor panel, which offers the advantage that sufficient spacecan be offered for a possible bending-out of the lip of the lowerhook-shaped part when performing the coupling movement.

It is particularly advantageous to form the locking parts as partswhich, during said downward movement, engage behind each other by meansof a snap action, and more particularly to form them in one piece in thematerial of the composed substrate. To wit, it is so that the composedsubstrate shows excellent features in order to smoothly position suchsnap portions behind each other when performing the coupling movement.

Preferably, even the aforementioned coupling parts substantially arerealized in the material of the floor panel, and more particularly insaid composed substrate, and preferably are made entirely in one piecetherewith.

The floor panel can be rectangular, either oblong or square, whereinsaid two opposite edges form a first pair of opposite edges and aparttherefrom the floor panel comprises a second pair of opposite edges,which also comprises coupling parts, which coupling parts allow alocking in a first direction perpendicular to the respective edges andin the plane of the floor panel, as well as in a second directionperpendicular to the plane of the floor panel.

The present invention is directed in particular to such floor panelwherein the coupling parts on the second pair of opposite edges areconfigured such that two of such floor panels can be coupled at thissecond pair of opposite edges by means of a turning movement of onefloor panel in respect to the other floor panel, in such a manner that aplurality of such floor panels can be coupled by means of a so-called“fold-down” technique. The advantages mentioned herein above will beclearly apparent in particular with such floor panels of the fold-downtype.

Preferably, said coupling parts on the second pair of opposite edgessubstantially are realized in the material of the floor panel itself andmore particularly in said composed substrate, and preferably are madeentirely in one piece therewith.

The floor panel preferably is oblong rectangular, wherein the first pairof opposite edges forms the short sides of the floor panel and thesecond pair of opposite edges forms the long sides of the floor panel.

In an alternative, the floor panel is oblong rectangular, wherein thefirst pair of opposite edges forms the long sides of the floor panel andthe second pair of opposite edges forms the short sides of the floorpanel.

It is noted that by “composed substrate”, also a composed substrateproduced in one piece has to be understood. Apart therefrom, it is notedthat the substrate layers of the composed substrate as such may also berealized multi-layered. In the case that such substrate layer isrealized multi-layered, these layers of the plurality of layers of thesubstrate layer in particular are similar to each other in that sensethat they consist of substantially the same materials and/or have thesame composition.

It is also noted that the locking surfaces do not necessarily have to beflat but can also, for example, be curved or bent. In the case thatthese locking surfaces are curved, they can there, where they cooperatein the coupled condition, define more than one tangent line, however, inaccordance with each of the six aspects, they have to define at leastone tangent line, which is horizontal or does not deviate more than 50degrees from the horizontal.

It is noted that by “massive” must be understood that no weakenedportions and/or recesses are provided in order to allow certaindeformations. Herein, it is also noted that by “substantially massive”is intended that, although such weakened portions and/or recesses arenot excluded, these extend only to a minor extent over the part in whichthey are provided.

It is noted that by “layers situated directly above each other”, it isnot excluded that possibly glue is present between these layers.

BRIEF DESCRIPTION OF THE DRAWINGS

With the intention of better showing the characteristics of theinvention, herein below, as an example without any limitative character,some preferred embodiments are described, with reference to theaccompanying drawings, wherein:

FIG. 1 in top view represents a floor panel according to the invention;

FIG. 2 represents a cross-section according to line II-II in FIG. 1,however, in the coupled condition of two of such floor panels, which canbe seen as an embodiment of at least the independent aspects 1, 2, 3, 4and 5;

FIG. 3 represents a variant of FIG. 2, which can be seen as anembodiment of at least the independent aspects 1, 2, 3, 4 and 6;

FIG. 4 represents a cross-section according to line IV-IV in FIG. 1,however, in the coupled condition of two of such floor panels;

FIG. 5 represents how such floor panels can be coupled by means of theso-called “fold-down” technique;

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

FIG. 1 represents a floor panel 1 according to the present invention.The floor panel 1 comprises coupling parts 5-6 on at least two oppositeedges 3-4.

FIG. 2 represents a cross-section according to line II-II in FIG. 1,however, in a coupled condition of two of such floor panels 1. The floorpanel 1 comprises a composed substrate 2, which in the example isrealized massive. The floor panel 1 further has a thickness T which issmaller than 10 mm and still better is in the order of magnitude of 8 mmor thinner.

The coupling parts 5-6 substantially are realized of the material of thecomposed substrate 2 and are made in one piece therewith.

The coupling parts 5-6 allow that two of such floor panels 1 can becoupled to each other by means of a downward movement M of one floorpanel 1 in respect to the other floor panel 1. In the coupled condition,the coupling parts 5-6 form a first locking system, which effects alocking in a first direction H in the plane of the floor panels 1 andperpendicular to the aforementioned edges 3-4, as well as a secondlocking system, which effects a locking in a second direction Vtransverse to the plane of the floor panels 1.

The first locking system is formed by an upward-directed lowerhook-shaped part 7 which is situated on the edge 4, as well as adownward-directed upper hook-shaped part 8 which is situated on theopposite edge 3. The hook-shaped parts 7-8 can be engaged behind eachother by means of the downward movement M. The lower hook-shaped part 7consists of a lip 9 with an upward-directed locking element 10, whereasthe upper hook-shaped part 8 consists of a lip 11 with adownward-directed locking element 12.

The locking elements 10 and 12 are made massive.

The second locking system comprises locking parts 13-14, whichrespectively are situated in the proximity of the proximal extremity ofthe lower hook-shaped part 7 and the distal extremity of the upperhook-shaped part 8.

The locking parts 13-14 are made as parts which, during said downwardmovement M, engage behind each other by means of snap action, whereinthese locking parts 13-14 here are made in one piece in the material ofthe composed substrate 2.

The distal extremity of the lower hook-shaped part 7 is free fromlocking parts, just like the proximal extremity of the upper hook-shapedpart 8. The distal extremity of the lower hook-shaped part 7 here evenis separated from the opposite floor panel 1 or from the opposite edge 3by means of a space S.

The composed substrate 2 consists of two substrate layers 15-16, to witha first synthetic material-based substrate layer 15 and a secondsubstrate layer 16 situated there above. The second substrate layer 16has a thickness D1 of at least 0.5 mm and preferably at least 1 mm. Thefirst substrate layer 15 has a density D2 of at least 3 mm, preferablyat least 4 mm and more preferably at least 5 mm.

The substrate layers 15-16 can show one or more of the followingcharacteristics:

-   -   the density of the first substrate layer 15 is different from        the density of the second substrate layer 16, and preferably the        second substrate layer 16 has a higher density than the first        substrate layer 15;    -   the first substrate layer 15 is foamed and preferably is of the        closed cell-type and still more preferably of the so-called hard        foam-type, and preferably the second substrate layer is not        foamed or is less foamed than the first substrate layer 15; the        first substrate layer 15 is extruded; and/or    -   both substrate layers 15-16 are glued to each other, preferably        by means of a waterproof glue.

In case that the first substrate layer 15 is foamed, this firstsubstrate layer 15 can be foamed gradually, wherein the degree offoaming, for example, increases in downward or in upward direction.

The substrate layers 15-16 further can be realized as described hereinabove in the introduction.

The locking parts 13-14 are provided with locking surfaces 17-18, which,there, where they cooperate in the coupled condition of two of suchfloor panels 1, define a tangent line R which is horizontal or does notdeviate more than 50 degrees from the horizontal. In the examplerepresented here, the tangent line R deviates approximately 25 degreesfrom the horizontal.

The locking surfaces 17-18 are situated closer to the upper side of thefirst substrate layer 15 than to the lower side of the first substratelayer 15. In the example represented here, the locking surfaces 17-18are situated entirely in the first substrate layer 15.

The upward-directed locking element 10 and the downward-directed lockingelement 12 are provided with locking surfaces 19-20. These lockingsurfaces 19-20, in the coupled condition of two of such floor panels 1,cooperate and prevent the moving apart of the floor panels 1 in thedirection H or at least counteract such moving apart of the floorpanels.

There, where the locking surfaces 19-20 cooperate in the coupledcondition of two of such floor panels 1, they define a tangent line R1,which is situated vertically or does not deviate more than 45 degreesfrom the vertical. In the example, the tangent line R1 is situatedvertically.

The locking distance A, which is formed by the horizontal distancebetween a vertical closing surface V1 formed between two of such coupledfloor panels 1 and a vertical plane V2 through the middle of the zoneover which the locking surfaces 19-20 make contact in the coupledcondition, is smaller than 1 cm, preferably smaller than 5 mm and morepreferably smaller than 3 mm.

The floor panel 1 also comprises a top layer 21, which in this exampleis situated above the second substrate layer 16. The top layer 21further can be realized such as described herein above in theintroduction.

FIG. 3 represents a variant of FIG. 2, wherein similar parts or elementsare indicated by the same reference numerals and letters as in FIG. 2.

As in FIG. 2, the composed substrate 2 in FIG. 3 consists of twosubstrate layers 15-16, which can be realized as described herein abovein the introduction.

The locking parts 13-14 are provided with locking surfaces 17-18, whichthere, where they cooperate in the coupled condition of two of suchfloor panels 1, define a tangent line R, which is horizontal or does notdeviate more than 50 degrees from the horizontal. In the examplerepresented here, the tangent line R deviates approximately 25 degreesfrom the horizontal.

There, where the locking surfaces 19-20 cooperate in the coupledcondition of two of such floor panels 1, they define a tangent line R1,which is situated vertically or does not deviate more than 45 degreesfrom the vertical. In the example, the tangent line R1 is situatedvertically.

The locking distance A is smaller than 1 cm, preferably smaller than 5mm and more preferably smaller than 3 mm.

Contrary to what is shown in FIG. 2, in FIG. 3 the locking surfaces17-18, however, are situated in the second substrate layer 16. However,they are situated closer to the upper side of the first substrate layer15 than to the lower side of the first substrate layer 15.

As represented in FIG. 1, the floor panel 1 is rectangular and here moreparticularly oblong. Apart from the pair of opposite edges 3-4, whichforms the pair of short sides of the floor panel 1, the floor panel 1also comprises a pair of opposite edges 22-23, which forms the pair oflong edges of the floor panel 1.

The pair of opposite edges 22-23 also comprises coupling parts 24-25.

FIG. 4 represents a cross-section according to line IV-IV in FIG. 1,however, in the coupled condition of two of such floor panels 1.

The coupling parts 24-25 allow effecting a locking in a direction Hperpendicular to the respective edges 22-23 and in the plane of thecoupled floor panels 1, as well as effecting a locking in a direction Vperpendicular to the plane of the coupled floor panels 1.

The coupling parts 24-25 are configured such that they allow couplingtwo of such floor panels 1 by means of a turning movement W.

The coupling parts 24-25 are manufactured substantially from thematerial of the composed substrate 2 and are made in one piecetherewith.

The coupling parts 24-25 substantially are made as a tongue 26 and agroove 27, which are provided with locking parts 28-29. These lockingparts 28-29 prevent the moving apart of the coupled floor panels 1according to the direction H or at least counteract such moving apart ofthe floor panels 1.

FIG. 5 represents how the floor panels 1 of FIG. 1 can be coupled bymeans of the so-called “fold-down” technique. In the figure, a partiallyfinished floor covering is shown with amongst others a row of alreadyinstalled floor panels 1A and a row with the already installed floorpanel 1B. The floor panel 1C is to be installed in the row of the floorpanel 1B and thus must be coupled to the floor panels 1A and 1B. Moreparticularly, the floor panel 1C must be coupled with its long edge 22to the long edges 23 of the floor panels 1A, and must be coupled withits short edge 3 to the short edge 4 of the floor panel 1B.

The fold-down movement is performed by turning the floor panel 1C, froman inclined position with its tongue 26 already partially introduced inthe groove 27 of the floor panels 1A, downward according to a movementW. With this movement, the long edges 22-23 are coupled to each otherand at the same time the short edges 3-4 are coupled by the downwardmovement M which is associated with the turning movement W. Thus, inother words, in one and the same movement W the floor panel 1, at itslong edge 22 as well as at its short edge 3, is coupled to the alreadyinstalled floor panels 1A-1B.

The present invention is in no way limited to the herein above-describedembodiments, on the contrary, such floor panels can be realizedaccording to various variants, without exceeding the scope of thepresent invention.

1. A floor panel comprising: a substrate; and a decorative layer locatedabove the substrate; wherein the substrate comprises a first substratelayer and a second substrate layer located above the first substratelayer; wherein the first substrate layer comprises a thermoplasticmaterial and a filling material; wherein the thermoplastic material ofthe first substrate layer is selected from a list containing polyvinylchloride, polyethylene, polypropylene, polyethylene terephthalate andpolyurethane; wherein the filling material of the first substrate layeris selected from a list containing bamboo, cork, wood, chalk, limestoneand talc; wherein the thermoplastic material of the first substratelayer is foamed; wherein the second substrate layer comprises athermoplastic material and a filling material; wherein the thermoplasticmaterial of the second substrate layer is selected from a listcontaining polyvinyl chloride, polyethylene, polyurethane, polypropyleneand polyethylene terephthalate; wherein the filling material of thesecond substrate layer is selected from a list containing chalk,limestone and talc; wherein the second substrate layer has a higherdensity than the first substrate layer; wherein the second substratelayer is not foamed or is less foamed than the first substrate layer;wherein the floor panel comprises on at least two opposite edgescoupling parts allowing two of such floor panels to be coupled to eachother by means of a downward movement of one floor panel with respect tothe other floor panel; wherein the coupling parts comprise a firstlocking system effecting a locking in a first direction in the plane ofthe panels and perpendicular to the edges and a second locking systemeffecting a locking in a second direction transverse to the plane of thepanels; wherein the first locking system comprises an upward-directedlower hook-shaped part situated on one of the opposite edges and adownward-directed upper hook-shaped part situated on the other of theopposite edges; wherein the hook-shaped parts are engageable behind eachother by means of said downward movement; wherein the lower hook-shapedpart comprises a lip with an upward-directed locking element and theupper hook-shaped part comprises a lip with a downward-directed lockingelement; wherein the locking elements comprise locking surfaceseffecting a locking in said first direction; and wherein the lockingsurfaces of the first locking system are at least partially formed inthe first substrate layer.
 2. The floor panel of claim 1, wherein thefoamed thermoplastic material of the first substrate layer is of theclosed-cell type.
 3. The floor panel of claim 1, wherein the foamedthermoplastic material of the first substrate layer is of the hard foamtype.
 4. The floor panel of claim 1, wherein the thermoplastic materialof the first substrate layer is foamed so that a density reduction of atleast 10% is obtained.
 5. The floor panel of claim 1, wherein the firstsubstrate layer is of the rigid type.
 6. The floor panel of claim 5,wherein the thermoplastic material of the first substrate layer ispolyvinyl chloride; and wherein the first substrate layer contains noplasticizers or plasticizers in an amount of less than 20 phr.
 7. Thefloor panel of claim 1, wherein the first substrate layer is an extrudedlayer.
 8. The floor panel of claim 1, wherein the second substrate layerhas a thickness of at least 0.5 mm.
 9. The floor panel of claim 1,wherein the floor panel comprises a backing layer located below thefirst substrate layer; and wherein the backing layer comprises amaterial selected from a list containing thermoplastic material, corkand rubber.
 10. The floor panel of claim 1, wherein the second lockingsystem comprises locking surfaces effecting a locking in said seconddirection; and wherein the locking surfaces of the second locking systemare at least partially formed in the first substrate layer.
 11. Thefloor panel of claim 1, wherein the second locking system compriseslocking surfaces effecting a locking in said second direction; andwherein the locking surfaces of the second locking system are at leastpartially formed in the second substrate layer.
 12. A floor panelcomprising: a substrate; and a decorative layer located above thesubstrate; wherein the substrate comprises a first substrate layer, asecond substrate layer located above the first substrate layer and areinforcement layer; wherein the first substrate layer comprisespolyvinyl chloride and a filling material; wherein the first substratelayer contains no plasticizers or plasticizers in an amount of less than20 phr; wherein the filling material of the first substrate layer isselected from a list containing bamboo, cork, wood, chalk, limestone andtalc. wherein the second substrate layer comprises polyvinyl chlorideand a filling material; wherein the filling material of the secondsubstrate layer is selected from a list containing chalk, limestone andtalc; wherein the floor panel comprises on at least two opposite edgescoupling parts allowing two of such floor panels to be coupled to eachother by means of a downward movement of one floor panel with respect tothe other floor panel; wherein the coupling parts comprise a firstlocking system effecting a locking in a first direction in the plane ofthe panels and perpendicular to the edges and a second locking systemeffecting a locking in a second direction transverse to the plane of thepanels; wherein the first locking system comprises an upward-directedlower hook-shaped part situated on one of the opposite edges and adownward-directed upper hook-shaped part situated on the other of theopposite edges; wherein the hook-shaped parts are engageable behind eachother by means of said downward movement; wherein the lower hook-shapedpart comprises a lip with an upward-directed locking element and theupper hook-shaped part comprises a lip with a downward-directed lockingelement; wherein the locking elements comprise locking surfaceseffecting a locking in said first direction; and wherein the lockingsurfaces of the first locking system are at least partially formed inthe first substrate layer.
 13. The floor panel of claim 12, wherein thesecond substrate layer has a thickness of at least 0.5 mm.
 14. The floorpanel of claim 12, wherein the reinforcement layer comprises glassfiber.
 15. The floor panel of claim 12, wherein the reinforcement layeris a glass fiber cloth.
 16. The floor panel of claim 12, wherein thefloor panel comprises a backing layer located below the first substratelayer; and wherein the backing layer comprises a material selected froma list containing thermoplastic material, cork and rubber.
 17. The floorpanel of claim 12, wherein the second locking system comprises lockingsurfaces effecting a locking in said second direction; and wherein thelocking surfaces of the second locking system are at least partiallyformed in the first substrate layer.
 18. The floor panel of claim 12,wherein the second locking system comprises locking surfaces effecting alocking in said second direction; and wherein the locking surfaces ofthe second locking system are at least partially formed in the secondsubstrate layer.